Inductive battery charging device for use with a surgical sterilizer

ABSTRACT

A retrofitting, inductive-battery-charging device for use with a surgical sterilization device, comprising an inductive charging assembly and an inductively powered battery-charging platform that is sterilizable inside a surgical sterilization device and is operable to charge at least one rechargeable battery of a battery-operated surgical instrument when the rechargeable battery is placed at the platform. The inductive charging assembly comprises an inductive-power-supply sub-assembly electrically connected to a power supply and is operable to supply power inductively over a distance at least equal to a width of a wall of the surgical sterilization device, and an inductive-power-receiver sub-assembly that is sterilizable inside the surgical sterilization device and electrically coupled to the platform. The inductive-power-receiver sub-assembly is operable to supply charging power to the platform for charging the at least one rechargeable battery when placed at the platform, and to inductively receive electrical power from the inductive-power-supply sub-assembly at least over the distance.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is:

-   -   a divisional application of U.S. application Ser. No.        12/878,508, filed on Sep. 9, 2010 (which application claims the        priority, under 35 U.S.C. §119, of U.S. Provisional Patent        Application Ser. No. 61/241,328, filed Sep. 10, 2009); and    -   a divisional application of U.S. application Ser. No.        12/879,651, filed on Sep. 10, 2010 (which application claims the        priority, under 35 U.S.C. §119, of U.S. Provisional Patent        Application Ser. No. 61/241,328, filed Sep. 10, 2009),        the entire disclosures of which are hereby incorporated herein        by reference in their entireties.

FIELD OF INVENTION

The present invention lies in the field of surgical sterilizationdevices and methods for the sterilization of surgical instruments. Thepresent disclosure relates specifically to a surgical sterilizer with anintegrated battery charging device and a method for surgicalsterilization while charging a battery, the battery being used in abattery-powered medical instrument or with a device used in surgicalprocedures. The surgical sterilization and the simultaneous charging ofthe battery occurs without compromising the sterile field by either theact of sterilizing or the act of charging the battery.

BACKGROUND OF THE INVENTION

A unique set of problems arise when a sterilized surgical device ormedical instrument also has a removable battery component that needs toperiodically removed from the device and recharged. Such batterycomponents do not stay within the sterile field of a singular operationas they are intended to be used for multiple and different surgicalprocedures on different patients. As such, to reduce the risk ofspreading disease and infection, the battery must be sterilized beforeit can be reused in another surgical procedure. If the battery componentis not sterilized prior to being connected to a sterile rechargingdevice, then there is a risk that any contaminants on the battery willspread to the recharging device once the non-sterile battery isconnected. If the battery is sterilized prior to being connected to therecharging device, then there is a risk that any contaminants existingon a non-sterile recharging device will spread to the battery.Therefore, it becomes necessary to use more than one sterilization cycleto maintain a sterile environment, which can be costly, time-consumingand harmful to the integrity of the battery.

If the battery is not sterilized at all and is removed from and insertedinto the device without contaminating the sterile field by successfullyimplementing aseptic transfer techniques that are known in the art,there still remains a risk that the recharging device will be exposed toany contaminants on the non-sterile battery, or vice versa, and serve asa source for spreading disease and infection. Accordingly, it would bedesirable to be able to sterilize objects including a rechargeablebattery while simultaneously charging it so that the sterility of thebattery is not compromised by the act of charging the battery and sothat the battery can be quickly recharged and sterilized in one stage,thereby returning the battery to use as quickly as possible.

There are existing prior art devices that recharge the batterycomponents inside surgical instruments while maintaining the alreadypre-existing sterile nature of the surgical instruments during the timethat the instrument is being recharged. For example, in U.S. Pat. No.6,666,875 to Sakurai et al., an apparatus is described that recharges asurgical instrument that has already been sterilized such that theapparatus maintains the pre-existing sterile nature of the instrumentwhile it is being recharged. The Sakurai et al. apparatus includes asurgical instrument, such as an ultrasonic knife, and a recharger. Therecharger is plugged into an electrical mains and an alternating currentis supplied to an output circuit that is connected to a powertransmission circuit that includes a power transmission coil.Electromagnetic energy is radiated outwards from the power transmissioncoil and into the surroundings. The surgical instrument has an internalrechargeable secondary battery and a power reception unit that includesa power reception coil that is wound about the battery chamber. Torecharge the Sakurai et al. instrument, electromagnetic energy isinduced in the power reception coil of the power reception unit by thepower transmission coil of the recharger. A rectification control unitconverts the electromagnetic energy received by the power reception unitinto direct current and adjusts the voltage to a level suitable forrecharging the secondary battery. Accordingly, electromagnetic energy isradiated outwards from the power transmission coil and into thesurroundings and is received by the power reception coil in thesecondary battery without requiring any physical contact between thesurgical instrument and the recharger. To maintain the sterile nature ofthe surgical instrument, the recharger has a separate sealed, sterilizedcontainer (for example, a vial) formed on the top of the recharger forholding the already sterilized surgical instrument while it is beingrecharged. This separate container must be transparent toelectromagnetic energy so that the electromagnetic energy being radiatedoutward from the recharger may be transmitted through the container andto the power reception coil in the secondary battery of the instrument.The container must be watertight and capable of being washed anddisinfected.

However, because these devices do not function to actively sterilize theinstruments and only serve to maintain the pre-existing sterile natureof the instruments, a costly and time-consuming two-stage process isstill required to reintroduce the instrument into a sterile, surgicalenvironment. The instrument must be sterilized in one stage andrecharged in a separate, second stage while in a sterile environment. Inaddition, the sealed, sterile container used to hold the instrumentwhile it is being charged must be cleaned and disinfected prior to andafter each time that it is used. Furthermore, there is no reliable andfail-safe indication on the container itself as to whether or not it hasbeen cleaned and disinfected prior to being used. As a result, there isstill a risk that the sterile nature of the instrument will becompromised. Thus, it would be beneficial to have a sterilizing devicethat not only sterilizes a removable, rechargeable battery of a surgicalinstrument but also recharges the battery simultaneously to ensure thatthe battery is both recharged and sterilized successfully in a singlestage and in the same environment.

In the prior art, there does exist one or more devices thatsimultaneously sterilize and recharge personal articles having batterycomponents in a single stage. For example, in U.S. Pat. No. 6,096,264 toPeifer, a device is described that is used to store, sterilize, andrecharge electric toothbrushes. The device is comprised of a cabinetthat includes a housing that encloses an internal sterilizing chamber.The internal sterilizing chamber has a microbe-destroying agent inside,such as a sterilizing lamp that emits ultraviolet (UV) radiation. Aholder is mounted inside the chamber and is comprised of a plurality ofreceptacles that receive and support the toothbrushes. Each receptaclehas associated recharging elements for recharging the toothbrush that isassociated with the receptacle. The recharging elements include pairs ofexposed contacts and covered induction coils. A plug and a power cordextend outside of the housing for connection to a domestic receptacle.Power from the cord is connected to an AC/DC converter, which, in turn,is connected to the contacts and coils of the receptacles. Accordingly,the battery components of the toothbrushes are inductively charged usingthe induction coils on the exposed contacts of the receptacles andsimultaneously, the toothbrushes are sterilized.

However, this device, as well as others, requires that the sterilechamber or housing be breached so that a power cord can be drawn intothe chamber or housing so that power can be provided to the electricalcontacts on the recharging elements. Therefore, only a certain degree ofsterility can be created or maintained by these devices, which, while itmay be suitable for personal articles such as toothbrushes, it is notsufficient in view of operating room standards (as legally mandated byregulatory agencies) and for valid sterilization of surgicalinstruments, referred to herein as “surgical sterilization.” Also, andsimilarly to the device described in Sakurai et al. and other deviceslike it, this device sterilizes the toothbrush or the instrument itselfand not the battery inside the toothbrush or instrument. Therefore, anon-sterile component is still present in the device even after thesterilization procedure has been completed. Accordingly, it would bedesirable to have a device that simultaneously sterilizes and rechargesa battery, whereby a power cord or other method of drawing power intothe sterilization chamber does not breach the surgical sterilizationchamber and therefore, is capable of sterilizing surgical instrumentsand the like, and directly recharges the battery.

In addition, the receptacles described in the Peifer device forreceiving and supporting the toothbrushes so that the toothbrushes canbe recharged necessarily cover a portion of the toothbrushes and shieldthe covered portion and the electrical contacts from the UV radiationthat sterilizes the toothbrush. Therefore, a portion of the toothbrushand the recharging elements of the device are not adequately exposed tothe UV radiation and, therefore, are not sufficiently sterilized.Accordingly, it would be desirable to have a device that simultaneouslysterilizes and recharges a battery that does not require obscuring aportion of the battery, the surgical instrument, or the rechargingelements of the device from the sterilizing components or agents.

It would also be advantageous to be able to adapt or retrofit existing(and, most likely, expensive) surgical sterilizing systems with thecapability of simultaneously recharging a battery to be sterilizedthereby allowing a surgeon or other operating room personnel to continueto use any conventional or standard sterilization system rather thanrequiring replacement of the conventional or standard systems. As aresult, the large expense and training time that would be required tooverhaul the existing sterilization systems would be avoided entirely.None of the devices described in the prior art, however, disclose suchan ability to recharge a sterilizable battery in an existingsterilization system.

Thus, a need exists to overcome the problems with the prior art asdiscussed above.

SUMMARY OF THE INVENTION

Embodiments of the present invention provide a retrofitting,inductive-battery-charging device for use with a surgical sterilizationdevice, the retrofitting charging device comprising an inductivelypowered battery-charging platform that is sterilizable inside a surgicalsterilization device and has at least one electrical contact shaped toconductively contact at least one corresponding electrical batterycontact of at least one rechargeable battery of a battery-operatedsurgical instrument when the rechargeable battery is placed at theplatform, a power supply operable to receive power from an electricmains, and an inductive charging assembly. The inductive chargingassembly comprises an inductive-power-supply sub-assembly electricallyconnected to the power supply and operable to supply power inductivelyover a distance at least equal to a width of a wall of the surgicalsterilization device, and an inductive-power-receiver sub-assembly thatis sterilizable inside the surgical sterilization device andelectrically coupled to the at least one electrical contact of theplatform. The inductive-power-receiver sub-assembly is operable tosupply charging power to the at least one electrical contact of theplatform for charging the at least one rechargeable battery when placedat the platform, and to inductively receive electrical power from theinductive-power-supply sub-assembly at least over the distance.

With the objects of the invention in view, the inductive-power-receiversub-assembly is operable to inductively receive electrical power fromthe inductive-power-supply sub-assembly when theinductive-power-receiver sub-assembly is disposed opposite theinductive-power-supply sub-assembly with at least the distanceseparating the two sub-assemblies.

In accordance with another feature of the present invention, theinductive-power-receiver sub-assembly is operable to inductively receiveelectrical power from the inductive-power-supply sub-assembly while atleast one of the inductively powered battery-charging platform and theinductive-power-receiver sub-assembly is being sterilized.

In accordance with yet another feature of the present invention, theinductive-power-receiver sub-assembly is operable to inductively receiveelectrical power from the inductive-power-supply sub-assembly while atleast one of the platform and the inductive-power-receiver sub-assemblyis inductively receiving electrical power for charging the at least onerechargeable battery.

In accordance with a further feature of the present invention, theinductive-power-supply sub-assembly comprises a first magnetic inductivecoil having a primary winding electrically coupled to the power supply,and the inductive-power-receiver sub-assembly comprises a secondmagnetic inductive coil having a secondary winding electrically coupledto the platform.

In accordance with another feature of the present invention, the secondmagnetic inductive coil is separated from the first magnetic inductivecoil at least by the distance.

In accordance with yet another feature of the present invention, whenthe second magnetic inductive coil is substantially aligned with thefirst magnetic inductive coil and the first magnetic inductive coil ispowered by power supply, the first magnetic inductive coil induces anelectrical current in the second magnetic inductive coil.

In accordance with another feature of the present invention, theinductive charging assembly does not breach a barrier disposed withinthe distance.

In accordance with another feature of the present invention, the firstand second magnetic inductive coils each have a magnetic core.

In accordance with another feature of the present invention, the firstand second magnetic inductive coils each have a ferrite core.

In accordance with yet another feature, an embodiment of the presentinvention further comprises an aligning component operable tosubstantially align the first and second magnetic inductive coils.

In accordance with yet another feature, an embodiment of the presentinvention further comprises an aligning component operable tosubstantially align the first and second magnetic inductive coils whenseparated over at least the distance.

In accordance with a further feature of the present invention, theinductive charging assembly further comprises an aligning componentoperable to substantially align the inductive-power-supply sub-assemblywith the inductive-power-receiver sub-assembly.

In accordance with another feature of the present invention, thealigning component is a set of magnets having magnetically oppositepoles.

In accordance with yet another feature of the present invention, theinductive charging assembly further comprises an aligning componentoperable to substantially align the inductive-power-supply sub-assemblywith the inductive-power-receiver sub-assembly when separated from oneanother over at least the distance.

In accordance with a further feature, an embodiment of the presentinvention further comprises a sealed container operable to enclose theat least one rechargeable battery to create a microbial seal around theat least one rechargeable battery, and to permit charging of the atleast one rechargeable battery while enclosing the at least onerechargeable battery in the microbial seal.

With the objects of the invention in view, there is also provided asurgical sterilization device having a selectively sealablesterilization enclosure with at least one wall, the improvementcomprising an inductively powered battery-charging platform capable thatis sterilizable inside the sterilization enclosure and has at least oneelectrical contact shaped to conductively contact at least onecorresponding electrical battery contact of at least one rechargeablebattery of a battery-operated surgical instrument when the rechargeablebattery is placed at the platform, a power supply operable to receivepower from an electric mains, and an inductive charging assembly. Theinductive charging assembly comprises an inductive-power-supplysub-assembly electrically connected to the power supply and operable tosupply power inductively into the sterilization enclosure from outsidethe sterilization enclosure through the wall, and aninductive-power-receiver sub-assembly that is sterilizable inside thesurgical sterilization device and electrically coupled to the at leastone electrical contact of the platform. The inductive-power-receiversub-assembly is operable to supply charging power to the at least oneelectrical contact of the platform for charging the at least onerechargeable battery when placed at the platform, and to inductivelyreceive electrical power from the inductive-power-supply sub-assemblythrough the wall.

In accordance with a feature of the present invention, the wall of thesurgical sterilization enclosure is permeable to electromagnetic waves.

With the objects of the invention in view, there is also provided aretrofitting, inductive-battery-charging device for surgicallysterilizing a battery of a battery-operated surgical instrument in aselectively sealable sterilization enclosure of a surgical sterilizationdevice, the retrofitting charging device comprising an inductivelypowered battery-charging platform sized and operable to be disposedinside the sterilization enclosure during sterilization and having acharger including at least one electrical contact shaped to conductivelycontact at least one corresponding electrical battery contact of atleast one rechargeable battery when the rechargeable battery is placedat the charger, and a power receiver sub-assembly electrically coupledto the at least one electrical contact of the charger. The powerreceiver sub-assembly being is operable to inductively receiveelectrical power to charge the at least one rechargeable battery whilethe rechargeable battery is being sterilized within the surgicalsterilization enclosure. In addition, a power supply is operable tosupply power inductively to the power receiver sub-assembly through thesurgical sterilization enclosure from outside the surgical sterilizationenclosure.

With the objects of the invention in view, there is further provided, incombination with a surgical sterilization device for surgicallysterilizing a battery of a battery-operated surgical instrument within aselectively sealable sterilization enclosure, aninductive-battery-charging device comprising an inductively poweredbattery-charging platform sized and operable to be disposed inside thesterilization enclosure during sterilization. The inductively poweredbattery-charging platform comprises a charger including at least oneelectrical contact shaped to conductively contact at least onecorresponding electrical battery contact of at least one rechargeablebattery when the rechargeable battery is placed at the charger, and apower receiver sub-assembly electrically coupled to the at least oneelectrical contact of the charger. The power receiver sub-assembly isoperable to inductively receive electrical power to charge the at leastone rechargeable battery while the rechargeable battery is beingsterilized within the surgical sterilization enclosure. In addition, apower supply is operable to supply power inductively to the powerreceiver sub-assembly through the surgical sterilization enclosure fromoutside the surgical sterilization enclosure.

With the objects of the invention in view, there is further provided, incombination with a surgical sterilization device having a selectivelysealable sterilization enclosure with at least one wall, a retrofitting,inductive-battery-charging device comprising an inductively poweredbattery-charging platform that is sterilizable inside the sterilizationenclosure and has at least one electrical contact shaped to conductivelycontact at least one corresponding electrical battery contact of atleast one rechargeable battery of a battery-operated surgical instrumentwhen the rechargeable battery is placed at the platform, a power supplyoperable to receive power from an electric mains, and an inductivecharging assembly. The inductive charging assembly comprises aninductive-power-supply sub-assembly electrically connected to the powersupply and operable to supply power inductively into the sterilizationenclosure from outside the sterilization enclosure through the at leastone wall, and an inductive-power-receiver sub-assembly that issterilizable inside the surgical sterilization device and electricallycoupled to the at least one electrical contact of the platform. Theinductive-power-receiver sub-assembly is operable to supply chargingpower to the at least one electrical contact of the platform forcharging the at least one rechargeable battery when placed at theplatform, and to inductively receive electrical power from theinductive-power-supply sub-assembly through the at least one wall.

Additional advantages and other features characteristic of the presentinvention will be set forth in the detailed description that follows andmay be apparent from the detailed description or may be learned bypractice of exemplary embodiments of the invention. Still otheradvantages of the invention may be realized by any of theinstrumentalities, methods, or combinations particularly pointed out inthe claims. The construction and method of operation of the invention,however, together with additional objects and advantages thereof, willbe best understood from the following description of specificembodiments when read in connection with the accompanying drawings.

Although the invention is illustrated and described herein as embodiedin a surgical sterilizer with an integrated battery charging device anda method for surgical sterilization while charging a battery, it is,nevertheless, not intended to be limited to the details shown becausevarious modifications and structural changes may be made therein withoutdeparting from the spirit of the invention and within the scope andrange of equivalents of the claims. Additionally, well-known elements ofexemplary embodiments of the invention will not be described in detailor will be omitted so as not to obscure the relevant details of theinvention.

Other features that are considered as characteristic for the inventionare set forth in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of embodiments of the present invention will be apparent fromthe following detailed description of the preferred embodiments thereof,which description should be considered in conjunction with theaccompanying drawings in which:

FIG. 1 is a block diagram of an exemplary embodiment of the sterilizerdevice according to the invention.

FIG. 2 is a fragmentary, perspective view of an exemplary embodiment ofan inductive magnetic coil of the sterilizer device of FIG. 1.

FIG. 3 is a fragmentary, side cross-sectional view of a wall of asterilization chamber of the device of FIG. 1 having an exemplaryembodiment of the inductive charging assembly applied thereon accordingto the present invention.

DETAILED DESCRIPTION OF THE INVENTION

As required, detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely exemplary of the invention, which can be embodied in variousforms. Therefore, specific structural and functional details disclosedherein are not to be interpreted as limiting, but merely as a basis forthe claims and as a representative basis for teaching one skilled in theart to variously employ the present invention in virtually anyappropriately detailed structure. Further, the terms and phrases usedherein are not intended to be limiting; but rather, to provide anunderstandable description of the invention. While the specificationconcludes with claims defining the features of the invention that areregarded as novel, it is believed that the invention will be betterunderstood from a consideration of the following description inconjunction with the drawing figures, in which like reference numeralsare carried forward. The figures of the drawings are not drawn to scale.

Before the present invention is disclosed and described, it is to beunderstood that the terminology used herein is for the purpose ofdescribing particular embodiments only and is not intended to belimiting. The terms “a” or “an,” as used herein, are defined as one ormore than one. The term “plurality,” as used herein, is defined as twoor more than two. The term “another,” as used herein, is defined as atleast a second or more. The terms “including” and/or “having,” as usedherein, are defined as comprising (i.e., open language). The term“coupled,” as used herein, is defined as connected, although notnecessarily directly, and not necessarily mechanically.

Relational terms such as first and second, top and bottom, and the likemay be used solely to distinguish one entity or action from anotherentity or action without necessarily requiring or implying any actualsuch relationship or order between such entities or actions. The terms“comprises,” “comprising,” or any other variation thereof are intendedto cover a non-exclusive inclusion, such that a process, method,article, or apparatus that comprises a list of elements does not includeonly those elements but may include other elements not expressly listedor inherent to such process, method, article, or apparatus. An elementproceeded by “comprises . . . a” does not, without more constraints,preclude the existence of additional identical elements in the process,method, article, or apparatus that comprises the element.

As used herein, the term “about” or “approximately” applies to allnumeric values, whether or not explicitly indicated. These termsgenerally refer to a range of numbers that one of skill in the art wouldconsider equivalent to the recited values (i.e., having the samefunction or result). In many instances these terms may include numbersthat are rounded to the nearest significant figure. In this document,the term “longitudinal” should be understood to mean in a directioncorresponding to an elongated direction of the object being described.

It is contemplated that the device, system, and method of the presentinvention may be used to sterilize and recharge various types ofbatteries that may be used in a wide range of battery-powered surgicalinstruments or medical devices. In an exemplary embodiment, the deviceand method of the present invention is used to sterilize and recharge aremovable and rechargeable battery of an endoscopic or laparoscopicsurgical device.

Referring now to the figures of the drawings in detail and first,particularly to FIG. 1 thereof, there is shown an exemplary embodimentof the surgical sterilizer with an integrated battery charging deviceaccording to the present invention. The sterilization device 1 iscomprised of a plurality of walls 8 that form a sealed enclosure 2 forthe surgical sterilization of an object, such as a battery 5.Accordingly, the sterilization device 1 has an interior surface 4 and anexterior surface 3.

In this particular embodiment, the sterilization device 1 isnon-magnetic, allows the transmission of electromagnetic waves throughit, and is sealed such that it is impervious to one or more sterilizingcomponents or agents. The components or agents for sterilizing thebattery 5 may be built into or integral with the sterilization device 1itself. Alternatively, the sterilization device 1 may be comprised of analready existing sterilization system that has been retrofitted with thebattery recharging capability provided for by the device and method ofthe present invention.

To sterilize the battery 5, the sterilization device 1 may have, builtin and integral therewith, one or more components or agents forsterilizing the battery. The one or more components or agents mayutilize high temperature (>100° C.) or chemical agents, or a combinationof both, in one or more vacuum, injection, washing, or ventilationcycles and/or phases. In general, the sterilization components or agentsshould be of a suitable type that does not short circuit the battery andis capable of permeating through a separate porous container thatencloses the battery, if such a separate container is used as describeddetail below. For example, the sterilization device 1 may employ variousautoclaving methods that use high-pressured steam, which are well knownin the art. Alternatively, or in combination with the high temperatureor high-pressured steam, various liquid and/or vapor chemical solutions,detergents, or disinfecting agents may be used. For example, ethyleneoxide gas (EtO), hydrogen peroxide (H₂O₂), or peracetic acid can beused. In another example, a combination of hydrogen peroxide vapor(H₂O₂) and low-temperature (<100° C.) gas plasma can be used. Thehydrogen peroxide acts as an oxidizing agent that affects sterilizationby oxidation of key cellular components and is a highly effectivebactericidal, virucidal, sporicidal, and fungicidal agent, even at lowconcentrations and temperatures. In yet another example, ultravioletlight or irradiation can be used to kill bacteria and other pathogensthat may be present on the battery. It will be understood by thosereasonably skilled in the art that a number of sterilization methods ortechniques may be incorporated into the device, system, and method ofthe present invention and the specific sterilization methods ortechniques described above are in no way intended as a limitation on thetypes of sterilizing methods or techniques that are contemplated by thedevice, system, and method of the present invention.

In an exemplary embodiment of the device and method of the presentinvention, the sterilization device 1 is comprised of any existingsterilizing system that employs a sealed enclosure 2. For example, thereare existing sterilization systems that include a single ormulti-tiered, sealed chamber that involves the combined use of hydrogenperoxide and low-temperature gas plasma for sterilizing a variety ofsingle-channel flexible endoscopes, semi-rigid ureteroscopes and a widerange of other instruments. A series of sterilization systems made byAdvanced Sterilization Products® (a Johnson & Johnson company) under theSTERRAD® product name utilizes this technology. In another example,there are existing sterilization systems that include a chamber in whicharticles are placed in a racking system to be sterilized using vaporizedhydrogen peroxide under vacuum conditions. The chamber is sealed using asilicone rubber gasket and a welded backhead, and utilizes an automaticdoor locking mechanism. An example of a sterilization system thatutilizes this technology is made by the STERIS® Corporation under theproduct name, AMSCO® V-PRO 1 Low Temperature Sterilization System. Inyet another example, other existing sterilization systems use one ormore ethylene oxide (EtO) sterilant cartridges and are designed for usein sterilizing heat and moisture-sensitive materials that are unable towithstand the high temperature of conventional steam sterilization.These systems include a gasket-sealed chamber such that the entiresterilization cycle operates under a vacuum. An example of this type ofsystem is the AMSCO®EAGLE® 3017 100% EO Sterilizer/Aerator, which isalso made by the STERIS® Corporation.

Referring now to FIGS. 1-3, the recharging components used to rechargethe battery 5 while the battery is being sterilized inside thesterilization enclosure 2 by the one or more sterilizing components oragents (not shown) are comprised of: (1) an inductive mains power supply13, (2) an inductive charging assembly 15, and (3) a battery-chargingplatform 7 positioned inside the sealed enclosure 2 of the sterilizationdevice 1. The battery-charging platform 7 has one or more electricalcontacts 21 that come into direct contact with the electrical contacts22 of battery 5 such that the battery is charged by the battery-chargingplatform 7 through conductive charging. In FIG. 1, the linesillustrating, diagrammatically, these respective electrical contactpairs 21 and 22 of the battery-charging platform 7 and the battery 5,are only exemplary and are not indicative of any particular conductivecontacting configuration or a particular number of contacts.

To provide electrical current to the electrical contacts 21 of thebattery-charging platform 7, the inductive mains power supply 13 and theinductive charging assembly 15 are used to supply the necessaryelectrical current across the sealed chamber wall 8 in such a way thatdoes not breach the sterilization enclosure 2. In the exemplaryembodiment shown in FIGS. 1-3, the inductive charging assembly 15 iscomprised of an inductive power supply sub-assembly and an inductivepower receiver sub-assembly, exemplary embodiments of each comprising afirst magnetic inductive coil 9 and a second magnetic inductive coil 10.The first magnetic inductive coil 9 is a transmitter coil and has aprimary winding 11. Similarly, the second magnetic inductive coil 10 isa power receiver or receiver coil and has a secondary winding 12. Eachof the first and second magnetic inductive coils 9, 10 has a magnetic“pot” core (e.g., a ferrite core).

The first magnetic inductive coil 9 of the inductive charging assembly15 is positioned at the exterior surface 3 of a wall 8 of thesterilization device 1 such that it is outside the sealed enclosure 2.Conversely, the second magnetic inductive coil 10 is positioned oppositethe first magnetic inductive coil 9 at the interior surface 4 of thewall 8 of the sterilization device 1 such that it is inside the sealedenclosure 2. The first magnetic inductive coil 9 is electrically coupledto the inductive mains power supply 13 by a wired connection 16, such asa cord. The inductive mains power supply 13, located outside of thesterilization enclosure 2, is electrically coupled to an electricalmains (not shown). Due to the magnetic properties of the first andsecond magnetic inductive coils 9 and 10, the two coils are magneticallyattracted to one another and, as a result, become substantially alignedacross the wall 8 of the sterilization device 1 such that they are inclose proximity to one another.

The first magnetic inductive coil 9, in connection with the inductivemains power supply 13, creates an electromagnetic field. Theelectromagnetic waves radiate from the first magnetic inductive coil 9and induce an electrical current in the secondary winding 12 of thesecond magnetic inductive coil 10 across the wall 8 of the sterilizationdevice 1. The electrical current that is induced in the second magneticinductive coil 10 is thereafter conducted to the electrical contacts 21of the battery-charging platform 7 using a wired connection 14, such asa cord. Accordingly, electrical power supplied from the outside of thesterilization enclosure 2 is conducted into the enclosure 2 forrecharging the battery 5 without, at any point, breaching the walls 8 ofthe sterilization device 1.

Now, because the battery-charging platform 7 is positioned inside thesealed enclosure 2 of the sterilization device 1 so that the battery 5may be recharged while simultaneously being sterilized, thebattery-charging platform 7 and the one or more electrical contacts 21contained therein must be comprised of materials that are suitable foruse inside the sterilizing enclosure 2. In other words, the sterilizingcomponents or agents cannot adversely affect the electrical or thestructural integrity of the battery-charging platform 7 and/or the oneor more electrical contacts 21 contained therein.

An exemplary embodiment of the first and second magnetic inductive coils9 and 10 is shown in detail in FIGS. 2 and 3. Each coil 9, 10 iscomprised of a circular housing 17 that has a hollow interior 18 and aspool-shaped column 19 that protrudes within the center of the housing17. At least a portion of the housing 17 is comprised of a magnetic“pot” core. The primary and secondary windings 11 and 12 of the firstand second magnetic inductive coils 9 and 10 are wound about thespool-shaped column 19 of the housings 17 in order to form the inductiveportion of coils 9 and 10.

An aligning component 20, such as a plurality of compact magnets, isplaced inside the hollow interior 18 of the housing 17 of each coil 9and 10 such that the two coils are magnetically coupled to one anotherwhen placed opposite each other across the wall 8 of the sterilizationdevice 1 as described above. The two coils 9 and 10 are alsomagnetically coupled to one another across the wall 8 by the magnetizingeffects of the inductive coupling that is described above once anelectrical current is applied. In FIGS. 2 and 3, the aligning component20 is shown as a ring of equidistantly positioned magnets that surroundsa center magnet. This particular configuration is only one exemplaryembodiment. Any aligning devices and methods can be used. For example,purely mechanical aligning devices are envisioned as well. Such a devicecould include an arc-shaped trough (not shown) in which the housings 17may be removably placed.

In addition, the battery 5 may be placed inside a separate, sealedcontainer (not shown) prior to placing the battery inside the sealedenclosure 2 of the sterilization device 1. The container may becomprised of a flexible bag or pouch or a rigid, semi-rigid or flexiblebox. In one embodiment, the container is comprised of materials that aresuitable for use inside the sterilization enclosure 2 and are porous tothe one or more sterilizing components or agents such that the one ormore sterilizing components or agents penetrate the container andeffectively sterilize the battery 5. At the same time, the materialscomprising the container must also be impervious to microbialcontaminants so as to form a microbial seal around the battery 5. Thismicrobial seal ensures that there is no cross-contamination between theelectrical contacts 22 of the battery and the one or more electricalcontacts 21 of the battery-charging platform 7 in circumstances wherethe sterilization components or agents cannot effectively reach theareas of the respective electrical contacts 22 and 21 while the battery5 and the battery-charging platform 7 are in physical contact with oneanother. Also, the container is comprised of a sufficiently conductivematerial or, has its own electrical contacts, such that the one or moreelectrical contacts 22 of the battery may be sealed inside the containerand still receive the electrical current flowing from the electricalcontacts 21 of the battery-charging platform 7. Examples of suchcontainers include Mylar® pouches and polypropylene wraps.Alternatively, a peel-back, molded, hard plastic component may beapplied to the electrical contacts 22 of the battery to form a microbialseal just at the contacts to prevent the occurrence ofcross-contamination as described above.

The foregoing description and accompanying drawings illustrate theprinciples, preferred embodiments and modes of operation of theinvention. However, the invention should not be construed as beinglimited to the particular embodiments discussed above. Additionalvariations of the embodiments discussed above will be appreciated bythose skilled in the art and the above-described embodiments should beregarded as illustrative rather than restrictive. Accordingly, it shouldbe appreciated that variations to those embodiments can be made by thoseskilled in the art without departing from the scope of the invention asdefined by the following claims.

1. A retrofitting, inductive-battery-charging device for use with asurgical sterilization device, the retrofitting charging devicecomprising: an inductively powered battery-charging platform that issterilizable inside a surgical sterilization device and has at least oneelectrical contact shaped to conductively contact at least onecorresponding electrical battery contact of at least one rechargeablebattery of a battery-operated surgical instrument when the rechargeablebattery is placed at the platform; a power supply operable to receivepower from an electric mains; and an inductive charging assembly having:an inductive-power-supply sub-assembly electrically connected to thepower supply and operable to supply power inductively over a distance atleast equal to a width of a wall of the surgical sterilization device;and an inductive-power-receiver sub-assembly that is sterilizable insidethe surgical sterilization device and electrically coupled to the atleast one electrical contact of the platform, theinductive-power-receiver sub-assembly being operable: to supply chargingpower to the at least one electrical contact of the platform forcharging the at least one rechargeable battery when placed at theplatform; and to inductively receive electrical power from theinductive-power-supply subassembly at least over the distance.
 2. Theretrofitting charging device according to claim 1, wherein theinductive-power-receiver sub-assembly is operable to inductively receiveelectrical power from the inductive-power-supply sub-assembly when theinductive-power-receiver sub-assembly is disposed opposite theinductive-power-supply sub-assembly with at least the distanceseparating the two sub-assemblies.
 3. The retrofitting charging deviceaccording to claim 1, wherein the inductive-power-receiver sub-assemblyis operable to inductively receive electrical power from theinductive-power-supply sub-assembly while at least one of theinductively powered battery-charging platform and theinductive-power-receiver sub-assembly is being sterilized.
 4. Theretrofitting charging device according to claim 1, wherein theinductive-power-receiver sub-assembly is operable to inductively receiveelectrical power from the inductive-power-supply sub-assembly while atleast one of the platform and the inductive-power-receiver sub-assemblyis inductively receiving electrical power for charging the at least onerechargeable battery.
 5. The retrofitting charging device according toclaim 1, wherein: the inductive-power-supply sub-assembly comprises afirst magnetic inductive coil having a primary winding electricallycoupled to the power supply; and the inductive-power-receiversub-assembly comprises a second magnetic inductive coil having asecondary winding electrically coupled to the platform.
 6. Theretrofitting charging device according to claim 5, wherein the secondmagnetic inductive coil is separated from the first magnetic inductivecoil at least by the distance.
 7. The retrofitting charging deviceaccording to claim 5, wherein, when the second magnetic inductive coilis substantially aligned with the first magnetic inductive coil and thefirst magnetic inductive coil is powered by power supply, the firstmagnetic inductive coil induces an electrical current in the secondmagnetic inductive coil.
 8. The retrofitting charging device accordingto claim 1, wherein the inductive charging assembly does not breach abarrier disposed within the distance.
 9. The retrofitting chargingdevice according to claim 5, wherein the first and second magneticinductive coils each have a magnetic core.
 10. The retrofitting chargingdevice according to claim 9, wherein the first and second magneticinductive coils each have a ferrite core.
 11. The retrofitting chargingdevice according to claim 5, further comprising an aligning componentoperable to substantially align the first and second magnetic inductivecoils.
 12. The retrofitting charging device according to claim 5,further comprising an aligning component operable to substantially alignthe first and second magnetic inductive coils when separated over atleast the distance.
 13. The retrofitting charging device according toclaim 1, wherein the inductive charging assembly further comprises analigning component operable to substantially align theinductive-power-supply sub-assembly with the inductive-power-receiversub-assembly.
 14. The retrofitting charging device according to claim13, wherein the aligning component is a set of magnets havingmagnetically opposite poles.
 15. The retrofitting charging deviceaccording to claim 1, wherein the inductive charging assembly furthercomprises an aligning component operable to substantially align theinductive-power-supply sub-assembly with the inductive-power-receiversub-assembly when separated from one another over at least the distance.16. The retrofitting charging device according to claim 1, furthercomprising a sealed container operable: to enclose the at least onerechargeable battery to create a microbial seal around the at least onerechargeable battery; and to permit charging of the at least onerechargeable battery while enclosing the at least one rechargeablebattery in the microbial seal.
 17. A surgical sterilization devicehaving a selectively sealable sterilization enclosure with at least onewall, the improvement comprising: an inductively poweredbattery-charging platform that is sterilizable inside the sterilizationenclosure and has at least one electrical contact shaped to conductivelycontact at least one corresponding electrical battery contact of atleast one rechargeable battery of a battery-operated surgical instrumentwhen the rechargeable battery is placed at the platform; a power supplyoperable to receive power from an electric mains; and an inductivecharging assembly having: an inductive-power-supply sub-assemblyelectrically connected to the power supply and operable to supply powerinductively into the sterilization enclosure from outside thesterilization enclosure through the wall; and aninductive-power-receiver sub-assembly that is sterilizable inside thesurgical sterilization device and electrically coupled to the at leastone electrical contact of the platform, the inductive-power-receiversub-assembly being operable: to supply charging power to the at leastone electrical contact of the platform for charging the at least onerechargeable battery when placed at the platform; and to inductivelyreceive electrical power from the inductive-power-supply sub-assemblythrough the wall.
 18. The retrofitting charging device according toclaim 17, wherein the wall is permeable to electromagnetic waves.
 19. Aretrofitting, inductive-battery-charging device for surgicallysterilizing a battery of a battery-operated surgical instrument in aselectively sealable sterilization enclosure of a surgical sterilizationdevice, the retrofitting charging device comprising: an inductivelypowered battery-charging platform sized and operable to be disposedinside the sterilization enclosure during sterilization and having: acharger including at least one electrical contact shaped to conductivelycontact at least one corresponding electrical battery contact of atleast one rechargeable battery when the rechargeable battery is placedat the charger; and a power receiver sub-assembly electrically coupledto the at least one electrical contact of the charger, the powerreceiver sub-assembly being operable to inductively receive electricalpower to charge the at least one rechargeable battery while therechargeable battery is being sterilized within the surgicalsterilization enclosure; and a power supply operable to supply powerinductively to the power receiver sub-assembly through the surgicalsterilization enclosure from outside the surgical sterilizationenclosure.
 20. In combination with a surgical sterilization device forsurgically sterilizing a battery of a battery-operated surgicalinstrument within a selectively sealable sterilization enclosure, aninductive-battery-charging device comprising: an inductively poweredbattery-charging platform sized and operable to be disposed inside thesterilization enclosure during sterilization and having: a chargerincluding at least one electrical contact shaped to conductively contactat least one corresponding electrical battery contact of at least onerechargeable battery when the rechargeable battery is placed at thecharger; and a power receiver sub-assembly electrically coupled to theat least one electrical contact of the charger, the power receiversub-assembly being operable to inductively receive electrical power tocharge the at least one rechargeable battery while the rechargeablebattery is being sterilized within the surgical sterilization enclosure;and a power supply operable to supply power inductively to the powerreceiver sub-assembly through the surgical sterilization enclosure fromoutside the surgical sterilization enclosure.
 21. In combination with asurgical sterilization device having a selectively sealablesterilization enclosure with at least one wall, a retrofitting,inductive-battery-charging device comprising: an inductively poweredbattery-charging platform that is sterilizable inside the sterilizationenclosure and has at least one electrical contact shaped to conductivelycontact at least one corresponding electrical battery contact of atleast one rechargeable battery of a battery-operated surgical instrumentwhen the rechargeable battery is placed at the platform; a power supplyoperable to receive power from an electric mains; and an inductivecharging assembly having: an inductive-power-supply sub-assemblyelectrically connected to the power supply and operable to supply powerinductively into the sterilization enclosure from outside thesterilization enclosure through the at least one wall; and aninductive-power-receiver sub-assembly that is sterilizable inside thesurgical sterilization device and electrically coupled to the at leastone electrical contact of the platform, the inductive-power-receiversub-assembly being operable: to supply charging power to the at leastone electrical contact of the platform for charging the at least onerechargeable battery when placed at the platform; and to inductivelyreceive electrical power from the inductive-power-supply sub-assemblythrough the at least one wall.